MR OILTAP R Installation And Commissioning Instructions

On-Load Tap-Changer
OILTAP® R

Installation and Commissioning Instructions

4427410/00 EN

© All rights reserved by Maschinenfabrik Reinhausen

Dissemination and reproduction of this document and use and disclosure of its content are strictly prohibited
unless expressly permitted.

Infringements will result in liability for compensation. All rights reserved in the event of the granting of patents,
utility models or designs.

The product may have been altered since this document was published.

We reserve the right to change the technical data, design and scope of supply.

Generally the information provided and agreements made when processing the individual quotations and orders
are binding.

The original operating instructions were written in German.

Table of contents

Table of contents

1 Introduction......................................................................................................................... 7

1.1 Validity................................................................................................................................................. 7

1.2 Manufacturer....................................................................................................................................... 7

1.3 Subject to change without notice......................................................................................................... 7

1.4 Completeness...................................................................................................................................... 7

1.5 Safekeeping......................................................................................................................................... 8

1.6 Notation conventions........................................................................................................................... 8

1.6.1 Symbols................................................................................................................................................................. 8

1.6.2 Hazard communication system............................................................................................................................. 9

1.6.3 Information system.............................................................................................................................................. 11

2 Safety................................................................................................................................. 12

2.1 General safety information................................................................................................................ 12

2.2 Appropriate use................................................................................................................................. 12

2.3 Inappropriate use............................................................................................................................... 13

2.4 Personnel qualification...................................................................................................................... 13

2.5 Operator's duty of care...................................................................................................................... 13

2.6 Personal protective equipment.......................................................................................................... 14

2.7 Protective devices............................................................................................................................. 15

2.7.1 Protective relay RS.............................................................................................................................................. 15

2.7.2 Pressure monitoring device................................................................................................................................. 15

2.7.3 Rupture disk ....................................................................................................................................................... 16

2.7.4 Pressure relief device MPreC®........................................................................................................................... 16

2.7.5 Tap-change supervisory control.......................................................................................................................... 16

2.7.6 Temperature monitoring...................................................................................................................................... 16

3 Product description.......................................................................................................... 17

3.1 Scope of delivery............................................................................................................................... 17

3.2 On-load tap-changer.......................................................................................................................... 17

3.2.1 Function description............................................................................................................................................ 17

3.2.2 Setup/versions..................................................................................................................................................... 18

3.2.3 Name plate.......................................................................................................................................................... 20

3.3 Drive shaft......................................................................................................................................... 21

3.3.1 Function description............................................................................................................................................ 21

3.3.2 Setup/models of drive shaft................................................................................................................................. 21

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Table of contents

3.4 RS protective relay............................................................................................................................ 24

3.4.1 Function description............................................................................................................................................ 24

3.4.2 Setup/models of protective relay......................................................................................................................... 24

3.5 Pressure monitoring device DW........................................................................................................ 26

3.5.1 Function description............................................................................................................................................ 26

3.5.2 Structure/versions of the pressure-operated relay.............................................................................................. 27

3.6 OF 100 Oil Filter Unit......................................................................................................................... 29

4 Packaging, transport and storage................................................................................... 30

4.1 Packaging.......................................................................................................................................... 30

4.1.1 Suitability............................................................................................................................................................. 30

4.1.2 Markings.............................................................................................................................................................. 30

4.2 Transportation, receipt and handling of shipments............................................................................ 31

4.3 Storage of shipments......................................................................................................................... 32

4.4 Unpacking shipments and checking for transportation damages...................................................... 33

5 Mounting............................................................................................................................ 34

5.1 Preparatory work............................................................................................................................... 34

5.1.1 Fitting mounting flange on transformer cover...................................................................................................... 35

5.1.2 Fitting stud bolts on mounting flange................................................................................................................... 35

5.2 Installing the standard version on-load tap-changer in the transformer............................................ 36

5.2.1 Fastening on-load tap-changer to transformer cover.......................................................................................... 36

5.2.2 Connecting tap winding and on-load tap-changer take-off lead.......................................................................... 44

5.2.3 Carrying out the transformer ratio test................................................................................................................. 48

5.2.4 Measuring DC resistance on transformer............................................................................................................ 51

5.2.5 Drying on-load tap-changer in autoclave............................................................................................................. 51

5.2.6 Drying on-load tap-changer in transformer tank.................................................................................................. 54

5.3 Installing the on-load tap-changer in the transformer (bell-type tank version)................................... 67

5.3.1 Inserting on-load tap-changer into supporting structure...................................................................................... 67

5.3.2 Connecting tap winding and on-load tap-changer take-off lead.......................................................................... 75

5.3.3 Carrying out the transformer ratio test................................................................................................................. 78

5.3.4 Measuring DC resistance on transformer............................................................................................................ 81

5.3.5 Drying on-load tap-changer in autoclave............................................................................................................. 81

5.3.6 Removing on-load tap-changer head.................................................................................................................. 84

5.3.7 Attaching bell-type tank and connecting on-load tap-changer head with on-load tap-changer........................... 90

5.3.8 Drying on-load tap-changer in transformer tank................................................................................................ 101

5.4 Filling the oil compartment of the on-load tap-changer with oil....................................................... 115

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5.5 Fitting protective devices and drive components............................................................................. 116

5.5.1 Connecting the tap-change supervisory control (if installed)............................................................................. 116

5.5.2 Installing protective relay in piping and connecting........................................................................................... 117

5.5.3 Installing and connecting the pressure-operated relay...................................................................................... 128

5.5.4 Fitting motor-drive unit....................................................................................................................................... 131

5.5.5 Fitting bevel gear............................................................................................................................................... 131

5.5.6 Fitting drive shaft............................................................................................................................................... 132

5.5.7 Centering on-load tap-changer and motor-drive unit......................................................................................... 162

5.5.8 Installing electrics for motor-drive unit............................................................................................................... 162

6 Commissioning the on-load tap-changer at the transformer manufacturer's site... 163

6.1 Bleeding on-load tap-changer head and suction pipe..................................................................... 163

6.1.1 Bleeding on-load tap-changer head.................................................................................................................. 163

6.1.2 Bleeding suction pipe on pipe connection S...................................................................................................... 164

6.2 Grounding the on-load tap-changer................................................................................................. 164

6.3 Performing tests on motor-drive unit............................................................................................... 165

6.4 Performing trial tap-change operations........................................................................................... 165

6.5 High-voltage tests on the transformer............................................................................................. 166

7 Transporting transformer to the operating site........................................................... 168

7.1 Transport with removed drive.......................................................................................................... 168

7.2 Transport with oil fill and without oil conservator............................................................................. 168

7.3 Transport without oil fill.................................................................................................................... 169

7.3.1 Emptying oil compartment via pipe connection S.............................................................................................. 169

8 Commissioning the transformer at the operating site................................................ 171

8.1 Checking motor-drive unit................................................................................................................ 171

8.2 Checking protective relay................................................................................................................ 172

8.2.1 Checking protective relay (RS 2001, 2001/V, 2001/H, 2001/E, 2001/5, 2001/R, 2003).................................... 172

8.2.2 Checking protective relay (RS 2004)................................................................................................................. 172

8.3 Checking pressure monitoring device............................................................................................. 172

8.4 Filling the oil compartment of the on-load tap-changer with oil....................................................... 173

8.5 Bleeding on-load tap-changer head and suction pipe..................................................................... 176

8.5.1 Bleeding on-load tap-changer head.................................................................................................................. 176

8.5.2 Bleeding suction pipe on pipe connection S...................................................................................................... 178

8.6 Performing trial tap-change operations........................................................................................... 178

8.7 Commissioning the transformer....................................................................................................... 179

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9 Fault elimination.............................................................................................................. 180

9.1 Tripping of the protective relay and re-commissioning the transformer........................................... 182

9.1.1 Flap valve in IN SERVICE position................................................................................................................... 183

9.1.2 Flap valve in OFF position................................................................................................................................. 183

9.1.3 Re-commissioning the transformer................................................................................................................... 183

9.2 Tripping the pressure-operated relay and putting the transformer back into operation................... 184

9.2.1 Sensor in the OPERATION position.................................................................................................................. 184

9.2.2 Sensor in the OFF position................................................................................................................................ 184

9.2.3 Re-commissioning the transformer................................................................................................................... 185

10 Technical data................................................................................................................. 186

10.1 Technical data for protective relay................................................................................................... 186

10.2 Special models of protective relay................................................................................................... 187

10.2.1 Protective relay with CO change-over contact as tripping switch ..................................................................... 187

10.2.2 Protective relay with several dry-reed magnetic switches................................................................................. 187

10.3 Technical data for pressure monitoring device................................................................................ 188

11 Appendix.......................................................................................................................... 189

11.1 Limit values for dielectric strength and water content of on-load tap-changer oil............................ 189

11.2 OILTAP® R, installation drawing for selector size C/D (896705).................................................... 190

11.3 OILTAP® R, installation drawing for selector size E (897873)........................................................ 191

11.4 OILTAP® R, R I 2002/2003-C/D, R I 3003-C/D, bridges for parallel connection of selector plane

(896706).......................................................................................................................................... 192

11.5 OILTAP® R, R I 2002/2003-E, R I 3003-E, bridges for parallel connection of selector plane (898713)

......................................................................................................................................................... 193

11.6 OILTAP® R, on-load tap-changer head (893899)........................................................................... 194

11.7 OILTAP® R, flange for pressure relief device (895168).................................................................. 195

11.8 Tracing template for on-load tap-changer head (890183)............................................................... 196

11.9 OILTAP® R, supporting flange for bell-type tank installation up to Um=300 kV (896762).............. 197

11.10 OILTAP® R, supporting flange for bell-type tank installation up to Um=362 kV (725912).............. 198

11.11 OILTAP® R, tap selector connection contacts and change-over selector connection contacts for

selector size E (897868).................................................................................................................. 199

11.12 Lifting traverse for bell-type tank installation (890180).................................................................... 200

11.13 Socket wrench for kerosene drain plug (890182)............................................................................ 201

11.14 Bevel gear CD 6400, dimensional drawing (892916)...................................................................... 202

Glossary........................................................................................................................... 203

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1 Introduction

Introduction

1

This technical file contains detailed descriptions of the safe and proper in­stallation, connection, and commissioning of the product.

It also includes safety instructions and general information about the prod­uct.

Information about operation can be found in the operating instructions.

This technical file is intended solely for specially trained and authorized per­sonnel.

Validity

1.1

The document supplied with the product is always the valid version. This
technical file is configured for the specific order and applies to the following
products, the serial numbers of which can be found on the delivery docu­ments:

▪ OILTAP® R type on-load tap-changer

▪ RS protective relay

▪ Pressure monitoring device DW 2000 (optional)

▪ Drive shaft

Manufacturer

1.2

The product is manufactured by:

Maschinenfabrik Reinhausen GmbH

Falkensteinstraße 8
93059 Regensburg, Germany
Tel.: [phone]
Fax: [phone]
E-mail: [e-mail]

Further information on the product and copies of this technical file are avail­able from this address if required.

Subject to change without notice

1.3

The information contained in this technical file comprises the technical speci­fications approved at the time of printing. Significant modifications will be in­cluded in a new edition of the technical file.

The document number and version number of this technical file are shown in
the footer.

Completeness

1.4

This technical file is incomplete without the supporting documentation.

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1 Introduction

The following documents apply:

▪ Unpacking instructions (included in the scope of delivery)

▪ Supplement (included in the scope of delivery)

▪ Routine test report (included in the scope of delivery)

▪ Connection diagrams (included in the scope of delivery)

▪ Dimensional drawings (included in the scope of delivery)

▪ Technical data - General section (available on request)

▪ Technical data - Product-specific section (available on request)

Also observe generally valid legislation, standards, and guidelines as well as
specifications on accident prevention and environmental protection in the re­spective country of use.

Safekeeping

1.5

This technical file and all supporting documents must be kept ready at hand
and accessible for future use at all times.

1.6

1.6.1

Notation conventions

This section contains an overview of the symbols and textual emphasis
used.

Symbols

Symbol Meaning

Wrench size

Tightening torque

Number and type of fastening materials used

Fill with oil

Cut open, cut through

Clean

Visual inspection

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1 Introduction

Symbol Meaning

Use your hand

Adapter ring

Apply a coat of paint

Use a file

Grease

Coupling bolt

1.6.2

1.6.2.1

Use a ruler

Use a saw

Hose clip

Wire eyelet, safety wire

Use a screwdriver

Table 1: Symbols

Hazard communication system

Warnings in this technical file are displayed as follows.

Warning relating to section

Warnings relating to sections refer to entire chapters or sections, sub-sec­tions or several paragraphs within this technical file. Warnings relating to
sections use the following format:

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1 Introduction

WARNING

1.6.2.2

1.6.2.3

Type and source of danger

Consequences

► Action

► Action

Embedded warning information

Embedded warnings refer to a particular part within a section. These warn­ings apply to smaller units of information than the warnings relating to sec­tions. Embedded warnings use the following format:

DANGER! Instruction for avoiding a dangerous situation.

Signal words and pictograms

The following signal words are used:

Signal
word

DANGER Indicates a hazardous situation which, if not avoided, will

WARNING Indicates a hazardous situation which, if not avoided, could

CAUTION Indicates a hazardous situation which, if not avoided, could

NOTICE Indicates measures to be taken to prevent damage to

Table 2: Signal words in warning notices

Meaning

result in death or serious injury.

result in death or serious injury.

result in injury.

property.

Pictograms warn of dangers:

Pictogram Meaning

Warning of a danger point

Warning of dangerous electrical voltage

Warning of combustible substances

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1 Introduction

Pictogram Meaning

Warning of danger of tipping

Table 3: Pictograms used in warning notices

1.6.3

Information system

Information is designed to simplify and improve understanding of particular
procedures. In this technical file it is laid out as follows:

Important information.

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Safety

2

General safety information

2.1

This technical file contains detailed descriptions of the safe and proper in­stallation, connection, and commissioning of the product.

▪ Read this technical file through carefully to familiarize yourself with the

product.

▪ Particular attention should be paid to the information given in this chap-

ter.

Appropriate use

2.2

If used as intended and in compliance with the requirements and conditions
specified in this technical file as well as the warning notices in this technical
file and attached to the product, then the product does not present any haz­ards to people, property or the environment. This applies throughout the
product's entire life, from delivery through installation and operation to disas­sembly and disposal.

2 Safety

DANGER

The operational quality assurance system ensures a consistently high quality
standard, particularly in regard to the observance of health and safety re­quirements.

The following is considered appropriate use

▪ Only operate the product in accordance with this technical file and the

agreed delivery conditions and technical data

▪ Use the equipment and special tools supplied solely for the intended

purpose and in accordance with the specifications of this technical file

▪ Use the product only with the transformer specified in the order

▪ You will find the standard valid for the product and the year of issue on

the name plate

▪ The serial numbers of on-load tap-changers and on-load tap-changer

accessories (drive, drive shaft, bevel gear, protective relay etc.) must
match if the on-load tap-changers and on-load tap-changer accessories
are supplied as a set for one order.

Danger of death or severe injury and damage to property and
the environment!

Danger of death or severe injury and damage to property and the environ­ment due to electrical voltage, falling and/or tipping parts as well as danger­ous cramped conditions resulting from moving parts!

► Adherence to the following prerequisites and conditions is mandatory.

► Adhere to warning notices.

Since the on-load tap-changer was dimensioned as per IEC 60214-1, it can
switch currents of up to twice the value of the rated through current.

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2 Safety

On-load tap-change operations are not to be performed during operating
conditions with higher currents.

Examples of such operating conditions are:

▪ Inrush current impulses when transformers are switched on

▪ Short circuit

The rated step voltage may be briefly exceeded by up to 10 % as long as the
rated through current is not exceeded. Such an operating condition can oc­cur due to overexcitation of the transformer after load shedding, for example.

The on-load tap-changer can be operated in the temperature range of the
surrounding transformer oil of between -25 ° and +105 °C and with overload
up to +115 °C in accordance with IEC 60214-1.

Inappropriate use

2.3

Use is considered to be inappropriate if the product is used other than as de­scribed in the Appropriate use section. Please also note the following:

▪ Risk of explosion and fire from highly flammable or explosive gases, va-

pors, or dusts. Do not operate product in areas at risk of explosion.

▪ Unauthorized or inappropriate changes to the product may lead to per-

sonal injury, material damage, and operational faults. Only modify prod­uct following discussion with Maschinenfabrik Reinhausen GmbH.

Personnel qualification

2.4

The product is designed solely for use in electrical energy systems and facili­ties operated by appropriately trained staff. This staff comprises people who
are familiar with the installation, assembly, commissioning and operation of
such products.

Operator's duty of care

2.5

To prevent accidents, disruptions and damage as well as unacceptable ad­verse effects on the environment, those responsible for transport, installa­tion, operation, maintenance and disposal of the product or parts of the prod­uct must ensure the following:

▪ All warning and hazard notices are complied with.

▪ Personnel are instructed regularly in all relevant aspects of operational

safety, the operating instructions and particularly the safety instructions
contained therein.

▪ Regulations and operating instructions for safe working as well as the

relevant instructions for staff procedures in the case of accidents and
fires are kept on hand at all times and are displayed in the workplace
where applicable.

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▪ The product is only used when in a sound operational condition and

safety equipment in particular is checked regularly for operational relia­bility.

▪ Only replacement parts, lubricants and auxiliary materials which are au-

thorized by the manufacturer are used.

▪ The specified operating conditions and requirements of the installation

location are complied with.

▪ All necessary devices and personal protective equipment for the specific

activity are made available.

▪ The prescribed maintenance intervals and the relevant regulations are

complied with.

▪ Installation, electrical connection and commissioning of the product may

only be carried out by qualified and trained personnel in accordance
with this technical file.

▪ The operator must ensure appropriate use of the product.

Personal protective equipment

2.6

2 Safety

Personal protective equipment must be worn during work to minimize risks to
health.

▪ Always wear the personal protective equipment required for the job at

hand.

▪ Follow information about personal protective equipment provided in the

work area.

Always wear

Protective clothing

Close-fitting work clothing with a low
breaking strength, with tight sleeves and
with no protruding parts. It mainly serves
to protect the wearer against being caught
by moving machine parts.

Do not wear any rings, necklaces or other
jewelry.

Safety shoes

To protect against falling heavy objects
and slipping on slippery surfaces.

Table 4: Personal protective equipment to be worn at all times

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2 Safety

Wear the following in spe­cial environments

Table 5: Personal protective equipment to be worn in special environments

Protective devices

2.7

Special personal protective equipment
is needed in special environments.

The choice of equipment depends on
the circumstances.

Safety glasses

To protect the eyes from flying parts and
splashing liquids.

Hard hat

To protect from falling and flying parts and
materials.

Hearing protection

To protect from hearing damage.

The following protective devices for the product are included as standard in
the scope of delivery or are available as options.

2.7.1

2.7.2

Protective relay RS

The protective relay RS is an oil flow-controlled relay in accordance with IEC
60214-1. It is installed between the on-load tap-changer head and the oil
conservator of the on-load tap-changer.

It triggers when the specified oil flow between oil compartment of the on-load
tap-changer and oil conservator is exceeded.

Pressure monitoring device

The pressure monitoring device DW 2000 is installed on the outside of the
on-load tap-changer and is tripped by unacceptable static and dynamic pres­sures in the on-load tap-changer oil vessel.

Additional use of a pressure-operated relay also requires installation of the
provided RS 2001 protective relay.

The features and characteristics of the pressure monitoring device comply
with the respective applicable version of IEC publication 60214-1.

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2 Safety

2.7.3

2.7.4

2.7.5

2.7.6

Rupture disk

The rupture disk is a pressure relief device without signaling contact in ac­cordance with IEC 60214-1 and is located in the on-load tap-changer head
cover.

The rupture disk responds to a defined overpressure in the oil compartment
of the on-load tap-changer.

Pressure relief device MPreC®

On request, in place of the rupture disk MR will supply a pre-fitted pressure
relief device MPreC® that responds to a defined overpressure in the oil com­partment of the on-load tap-changer.

The on-load tap-changer therefore meets the requirements of IEC 60214-1
regarding pressure relief devices.

Tap-change supervisory control

The tap-change supervisory control monitors both the drive shaft between
on-load tap-changer(s) and motor-drive unit and the correct switching of the
diverter switch.

Temperature monitoring

The temperature monitoring device monitors the oil temperature in the oil
compartment of the on-load tap-changer.

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3 Product description

Product description

3

This chapter contains an overview of the design and function of the product.

Scope of delivery

3.1

The product is packaged with protection against moisture and is usually de­livered as follows:

▪ Oil compartment with on-load tap-changer head and built-in diverter

switch insert

▪ Selector

▪ Motor-drive unit

▪ Drive shaft with coupling parts and bevel gear

▪ Protective device

▪ Technical files

Please refer to the delivery slip for full details of scope of delivery.

Single-phase on-load tap-changers are also available as an on-load tap­changer set with a common motor-drive unit.

3.2.1

Note the following information:

▪ Check the shipment for completeness on the basis of the shipping docu-

ments.

▪ Store the parts in a dry place until installation.

▪ The product must remain in its airtight, protective wrapping and may on-

ly be removed immediately before installation

You will find more information in the "Packaging, transport, and storage"
[► 30] chapter.

On-load tap-changer

3.2

Function description

On-load tap-changers are used to adjust the transmission ratio of transform­ers without interrupting the load flow. Fluctuations in voltage occurring in the
power transmission grid, for example, can therefore be compensated for. For
this purpose, on-load tap-changers are fitted in transformers and connected
to the active part of the transformer.

A motor-drive unit, which receives a control impulse (e.g. from a voltage reg­ulator), changes the on-load tap-changer's operating position, as a result of
which the transmission ratio of the transformer is adapted to the operating
requirements.

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3 Product description

3.2.2

Figure 1: System overview of on-load tap-changer transformer

1 Transformer tank 6 Gear unit

2 Motor-drive unit 7 On-load tap-changer

3 Vertical drive shaft 8 Protective relay

4 Bevel gear 9 Oil conservator

5 Horizontal drive shaft 10 Active part

Setup/versions

The on-load tap-changer consists of the on-load tap-changer head, oil com­partment with built-in diverter switch insert, and the tap selector mounted be­low (also available with change-over selector on request).

The design and designation of the most important on-load tap-changer com­ponents are shown in the installation drawings in the appendix.

For the number of maximum operating positions of the on-load tap-changer,
refer to the technical data.

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3 Product description

3.2.2.1

Figure 2: OILTAP® R on-load tap-changer

1 On-load tap-changer head 3 Tap selector

2 Oil compartment 4 Change-over selector

Pipe connections

The on-load tap-changer head features 4 pipe connections for different pur­poses.

Depending on the order, some or all of these pipe connections are fitted with
pipe bends ex factory. All pipe bends without terminal box for the tap-change
supervisory control can be freely swiveled once the pressure ring is loos­ened.

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3 Product description

Figure 3: Pipe connections with pipe bends

Pipe connection Q

Pipe connection Q is closed with a blank cover and, depending on the on­load tap-changer type, is intended for the bushing of the tap-change supervi­sory control supplied as an option or for connecting the oil filter unit.

The functions of the R and Q pipe connections can be interchanged.

Pipe connection S

The pipe bend on pipe connection S features a vent screw and can be con­nected to a pipe that ends with a drain valve on the side of the transformer
tank at operating height. If the on-load tap-changer is fitted with an oil suc­tion pipe, the on-load tap-changer can be completely emptied via pipe con­nection S.

Pipe connection R

Pipe connection R is provided for the attachment of the protective relay and
the connection of the on-load tap-changer oil conservator and can be inter­changed with pipe connection Q.

Pipe connection E2

The pipe connection E2 is closed with a blank cover. It leads into the oil tank
of the transformer, directly under the on-load tap-changer head and can be
connected to a collective pipe for the Buchholz relay, if necessary. This pipe
connection serves a further purpose, namely to equalize the pressure be­tween the transformer tank and oil compartment of the on-load tap-changer,
which is necessary for drying and transportation of the transformer.

3.2.3

Name plate

The name plate is on the on-load tap-changer head cover.

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3 Product description

Figure 4: Position of name plate

Drive shaft

3.3

3.3.1

3.3.2

Function description

The drive shaft is the mechanical connection between motor-drive and on­load tap-changer head / off-circuit tap-changer head.

The bevel gear changes the direction from vertical to horizontal (see drawing

892916).

Accordingly, the vertical drive shaft has to be mounted between drive and
bevel gear and the horizontal drive shaft between bevel gear and on-load
tap-changer or off-circuit tap-changer.

Setup/models of drive shaft

The drive shaft consists of a square tube and is coupled by two coupling
brackets and one coupling bolt at both ends to the drive / driven shaft end of
the device to be connected.

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3 Product description

3.3.2.1

3.3.2.2

Drive shaft without cardan shaft, without insulator (= normal model)

Figure 5: Drive shaft without cardan shaft, without insulator (= normal model)

Configuration V 1 min

[mm]

Middle of hand crank – middle

536 V 1 > 2,472

Intermediate bearing
for [mm]

of bevel gear (maximum per­missible axial offset 2°)

Drive shaft without cardan shaft, with insulator (= special model)

Figure 6: Drive shaft without cardan shaft, with insulator (= special model)

Configuration V 1 min

[mm]

Middle of hand crank – middle

706 V 1 > 2472

Intermediate bearing
for [mm]

of bevel gear (maximum per­missible axial offset 2°)

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3 Product description

3.3.2.3

3.3.2.4

Drive shaft with cardan shaft, without insulator (= special model)

Figure 7: Drive shaft with cardan shaft, without insulator (= special model)

Configuration V 1 min

[mm]

Middle of hand crank – middle

798 V 1 > 2,564

Intermediate bearing
for [mm]

of bevel gear (maximum per­missible axial offset alpha =
20°)

Drive shaft with cardan shaft, with insulator (= special model)

Figure 8: Drive shaft with cardan shaft, with insulator (= special model)

Configuration V 1 min

[mm]

Middle of hand crank – middle

978 V 1 > 2,772

Intermediate bearing
for [mm]

of bevel gear (maximum per­missible axial offset alpha =
20°)

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RS protective relay

3.4

3 Product description

3.4.1

Function description

The protective relay is used to protect the on-load tap-changer and the
transformer when a malfunction occurs in the diverter switch oil compartment
or selector switch oil compartment. It is tripped when the specified speed of
oil flow from the on-load tap-changer head to the oil conservator is exceeded
due to a fault. The flowing oil actuates the flap valve which tips over into po­sition OFF. The contact in the dry-reed magnetic switch is thereby actuated,
the circuit breakers are tripped, and the transformer is de-energized.

The protective relay is part of an oil-insulated on-load tap-changer and its
properties conform to the applicable valid version of IEC publication
60214-1. Therefore, it is part of the scope of our delivery.

Diverter switch operations at rated switching capacity or at permissible over­load will not cause the protective relay to trip.

The protective relay responds to oil flow, not to gas accumulated in the pro­tective relay. It is not necessary to bleed the protective relay when filling the
transformer with oil. Gas accumulation in the protective relay is normal.

3.4.2

Front view

Setup/models of protective relay

Figure 9: RS 2001

1 Inspection window

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3 Product description

Rear view

Figure 10: RS 2001

1 Dummy plug 3 Ventilation for terminal box

2 Identification plate

The protective relay RS 2001/R has an extra inspection window on the rear.

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View from above

3 Product description

Figure 11: RS 2001

1 Gasket 7 Cable connection

2 Grounding cable 8 Protective cover

3 Terminal box cover 9 Dummy plug

4 OPERATION (reset) test but-

ton

5 Slotted head screw 11 Cylinder head screw for pro-

6 OFF (test tripping) test button

The protective relay RS 2003 and RS 2004 has a 1/2"-14NPT adapter in
place of the cable connection (position 7).

3.5.1

Pressure monitoring device DW

3.5

Function description

The DW 2000 pressure-operated relay protects the on-load tap-changer
from unacceptable pressure increases, contributing to the safety of the
transformer. The pressure-operated relay is installed on the outside of the
on-load tap-changer and is tripped by unacceptable static and dynamic pres­sures in the on-load tap-changer oil vessel.

10 Connection terminals

tective conductor connection

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3 Product description

The pressure-operated relay works on the same principle as a barometric
corrugated tube with a counter-pressure spring and a mechanically linked
snap-action switch. The sensor on the snap-action switch snaps to the other
position by itself after tripping and has to be reset into the initial position by
hand.

The pressure increase activates the sensor on the snap-action switch that
flips into the OFF position. This triggers the circuit breaker and de-energizes
the transformer.

Low-energy interference does not cause the pressure-operated relay to trip
since the required tripping pressure is not reached. The tripping pressure is
set at the factory and prevented from being changed.

The pressure-operated relay responds faster than the RS 2001 protective re­lay in relation to large pressure increases. The RS 2001 protective relay is
part of the default MR protection system that comes standard.

Additional use of a pressure-operated relay also requires installation of the
provided RS 2001 protective relay.

3.5.2

The features and characteristics of the pressure-operated relay comply with
the respective applicable version of IEC publication 60214-1.

Diverter switch operations at the rated switching capacity or permitted over­load do not cause the pressure-operated relay to trip.

The pressure-operated relay responds to a pressure change and not to gas
accumulation under the pressure-operated relay. Gas accumulation under
the pressure-operated relay is normal.

Structure/versions of the pressure-operated relay

This chapter gives you an overview of the structure of the pressure-operated
relay.

The pressure-operated relay consists of a pressure measuring element and
an adjacent snap-action switch.

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3 Product description

Figure 12: Snap-action switch and pressure measuring element

1 Snap-action switch 2 Pressure measuring element

The snap-action switch has a normally open switch and normally closed
switch with snap action.

During operation, the snap-action switch and pressure measuring element
are protected by a cover cap. Ventilation is provided on the top of the pres­sure-operated relay.

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3 Product description

Figure 13: Pressure-operated relay with cover cap and ventilation

1 Ventilation 2 Cover cap

There are two variants of the pressure-operated relay

▪ DW 2000 for vertical installation and fastening on the on-load tap-

changer head

▪ DW 2000 for horizontal installation and fastening on a pipe bend

The housing and the cover cap of the pressure-operated relay consist of
lightweight, corrosion-resistant metal.

OF 100 Oil Filter Unit

3.6

Along with the paper filter insert, the purpose of the OF 100 oil filter unit is to
clean the on-load tap-changer's insulating oil and, with the combined filter in­sert, to clean and dry it.

If the number of tap-change operations per year is 15,000 or higher, we rec­ommend the use of the OF 100 oil filter unit with paper filter insert. The main­tenance intervals can therefore be extended.

For more information, consult the MR operating instructions "OF 100 oil filter
unit".

You must use the OF 100 oil filter unit with combined filter insert for
OILTAP® R on-load tap-changers with operating voltage Ub from 245 kV and
voltage for equipment Um from 300 kV.

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4 Packaging, transport and storage

Packaging, transport and storage

4

Packaging

4.1

The products are sometimes supplied with a sealed packaging and some­times also dried depending on what is required.

A sealed packaging surrounds the packaged goods on all sides with plastic
foil. Products that have also been dried are identified by a yellow label on the
sealed packaging.

The information in the following sections should be applied as appropriate.

4.1.1

NOTICE

4.1.2

Suitability

Property damage due to incorrectly stacked crates!

Stacking the crates incorrectly can lead to damage to the packaged goods!

► Only stack up to 2 equally sized crates on top of one another.

The packaging is suitable for undamaged and fully functional means of
transportation in compliance with local transportation laws and regulations.

The packaged goods are packed in a stable crate. This crate ensures that
when in the intended transportation position the packaged goods are stabi­lized to prevent impermissible changes in position, and that none of the parts
touch the loading surface of the means of transport or touch the ground after
unloading.

A sealed packaging surrounds the packaged goods on all sides with plastic
foil. The packaged goods are protected from humidity using a desiccant. The
plastic foil is bonded after the drying agent is added.

Markings

The packaging bears a signature with instructions for safe transport and cor­rect storage. The following symbols apply to the shipment of non-hazardous
goods. Adherence to these symbols is mandatory.

Protect
against

moisture

Table 6: Shipping pictograms

Top Fragile Attach lifting

Center of

gear here

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mass

4 Packaging, transport and storage

Transportation, receipt and handling of shipments

4.2

WARNING

Danger of death and damage to property!

Danger of death and damage to property due to tipping or falling load!

► Transport crate only when closed.

► Do not remove the mounting material used in the crate during transport.

► Only trained and appointed persons may select the sling gear and se-

cure the load.

► Do not walk under the hanging load.

► Use means of transport and lifting gear with a sufficient carrying capaci-

ty in accordance with the weight stated on the delivery slip.

In addition to oscillation stress and shock stress, jolts must also be expected
during transportation. In order to prevent possible damage, avoid dropping,
tipping, knocking over and colliding with the product.

If a crate tips over, falls from a certain height (e.g. when slings tear) or expe­riences an unbroken fall, damage must be expected regardless of the
weight.

Every delivered shipment must be checked for the following by the recipient
before acceptance (acknowledgment of receipt):

▪ Completeness based on the delivery slip

▪ External damage of any type.

Visible damage

The checks must take place after unloading when the crate or transport con­tainer can be accessed from all sides.

If external transport damage is detected on receipt of the shipment, proceed
as follows:

▪ Immediately record the transport damage found in the shipping docu-

ments and have this countersigned by the carrier.

▪ In the event of severe damage, total loss or high damage costs, immedi-

ately notify the sales department at Maschinenfabrik Reinhausen and
the relevant insurance company.

▪ After identifying damage, do not modify the condition of the shipment

further and retain the packaging material until an inspection decision
has been made by the transport company or the insurance company.

▪ Record the details of the damage immediately onsite together with the

carrier involved. This is essential for any claim for damages!

▪ Photograph damage to packaging and packaged goods. This also ap-

plies to signs of corrosion on the packaged goods due to moisture inside
the packaging (rain, snow, condensation).

▪ NOTICE! Be absolutely sure to also check the sealed packaging. If the

sealed packaging is damaged, do not under any circumstances install or
commission the packaged goods. Either dry the dried packaged goods
again as per the operating instructions for the relevant on-load tap-

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4 Packaging, transport and storage

changer/off-circuit tap-changer or contact Maschinenfabrik Reinhausen
GmbH to agree on how to proceed with drying. If this is not done, the
packaged goods may be damaged.

▪ Name the damaged parts.

Hidden damage

4.3

When damages are not determined until unpacking after receipt of the ship­ment (hidden damage), proceed as follows:

▪ Make the party responsible for the damage liable as soon as possible by

telephone and in writing, and prepare a damage report.

▪ Observe the time periods applicable to such actions in the respective

country. Inquire about these in good time.

With hidden damage, it is very hard to make the transportation company (or
other responsible party) liable. Any insurance claims for such damages can
only be successful if relevant provisions are expressly included in the insur­ance terms and conditions.

Storage of shipments

Packaged goods dried by Maschinenfabrik Reinhausen

Upon receipt of the shipment, immediately remove the packaged goods
dried by Maschinenfabrik Reinhausen from the sealed packaging and store
air-tight in dry insulating oil until used.

Non-dried packaged goods

Non-dried packaged goods but with a functional sealed packaging can be
stored outdoors when the following conditions are complied with.

When selecting and setting up the storage location, ensure the following:

▪ Protect stored goods against moisture (flooding, water from melting

snow and ice), dirt, pests such as rats, mice, termites and so on, and
against unauthorized access.

▪ Store the crates on timber beams and planks as a protection against ris-

ing damp and for better ventilation.

▪ Ensure sufficient carrying capacity of the ground.

▪ Keep entrance paths free.

▪ Check stored goods at regular intervals. Also take appropriate action af-

ter storms, heavy rain or snow and so on.

Protect the packaging foil from direct sunlight so that it does not disintegrate
under the influence of UV rays, which would cause the packaging to lose its
sealing function.

If the product is installed more than 6 months after delivery, suitable meas­ures must be taken without delay. The following measures can be used:

▪ Correctly regenerate the drying agent and restore the sealed packaging.

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4 Packaging, transport and storage

▪ Unpack the packed goods and store in suitable storage space (well ven-

Unpacking shipments and checking for transportation

4.4
damages

▪ NOTICE! Transport the packaged crate to the place where installation

▪ WARNING! When unpacking, check the condition of the packaged

▪ Check completeness of supplementary parts on the basis of the delivery

tilated, as dust-free as possible, humidity < 50 % where possible).

will take place. Do not open the sealed packaging until just before instal­lation. If this is not done, damage to the packaged goods may occur due
to ineffectively sealed packaging.

goods.Secure packaged goods in an upright crate from tipping out. If
this is not done, the packaged goods may be damaged and serious inju­ries may result.

slip.

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Mounting

5

5 Mounting

WARNING

Risk of crushing from moving parts!

When the on-load tap-changer undertakes a tap-change operation, compo­nents move on the selector and change-over selector, some of which are
freely accessible. Reaching into the selector or change-over selector during
a tap-change operation may result in serious injuries.

► Keep at a safe distance of at least 1 m during tap-change operations.

► Do not reach into the selector or change-over selector during tap-

change operations.

► Do not switch the on-load tap-changer when working on the selector

and change-over selector.

This chapter describes how to install the on-load tap-changer in a transform­er and how to dry it. Installation in both a standard version transformer and a
bell-type tank transformer is described. Regardless of the transformer ver­sion, undertake the preparatory work before starting to install the on-load
tap-changer in the transformer.

Preparatory work

5.1

Perform the work stated below before installing the on-load tap-changer in
the transformer.

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5 Mounting

5.1.1

Fitting mounting flange on transformer cover

A mounting flange is required for fitting the on-load tap-changer head on the
transformer cover. This can be supplied as an option or can be produced by
the customer. Mounting flanges made by the customer must comply with the
installation drawings in the appendix.

► NOTICE! Fit mounting flange on transformer cover (pressure tight).En-

sure that the sealing face makes complete contact and is not damaged.

5.1.2

Figure 14: Mounting flange

Fitting stud bolts on mounting flange

To attach the stud bolts to the mounting flange, use a tracing template. This
can be provided upon request free of charge for the initial installation of the
on-load tap-changer.

1. Place tracing template on mounting flange and use the four markings to

align.

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2. Fit stud bolts on mounting flange.

5 Mounting

5.2

5.2.1

5.2.1.1

Figure 15: Tracing template, stud bolts

Installing the standard version on-load tap-changer in the transformer

Perform the work stated below in order to install the on-load tap-changer in
the transformer (standard version).

Fastening on-load tap-changer to transformer cover

This chapter describes how to fasten the on-load tap-changer to the trans­former cover.

Fastening oil compartment on transformer cover

1. CAUTION! Place the oil compartment on a level surface and secure
it against tipping. An unstably positioned oil compartment may tip over,
resulting in serious injuries and damage.

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5 Mounting

2. Remove red-colored packaging material and transport material from oil
compartment.

3. Clean sealing surfaces on mounting flange and on-load tap-changer
head, place oil-resistant gasket on mounting flange.

Figure 16: Sealing surfaces, seal

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5 Mounting

4. NOTICE! Lift the oil compartment by hooking up the on-load tap-chang­er head and carefully lower the oil compartment into the cover opening
of the transformer. When lowering, take care not to damage the screen­ing rings (only present if Um ≥ 170 kV).

Figure 17: Oil compartment

5. Check that the on-load tap-changer head is mounted in the position
specified by the design.

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5 Mounting

6. Screw on-load tap-changer head to mounting flange.

Figure 18: On-load tap-changer head with mounting flange

7. Remove the blocking device from the coupling of the oil compartment
base.

Figure 19: Blocking plate and shackle

5.2.1.2

Securing selector on oil compartment (selector size C/D)

1. CAUTION! Place the selector on a level surface and secure it
against tipping. An unstably positioned selector may tip, resulting in seri­ous injuries and damage.

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5 Mounting

2. Remove red-colored packaging material and transport material from se­lector.

3. Remove plastic bag with fastening materials from the selector and keep
them ready.

Figure 20: Plastic bag with fastening materials

4. Remove the blocking strip from the selector coupling. Once the blocking
strip is removed, the selector coupling must no longer be turned.

Figure 21: Blocking strip

5. Place the selector on the lifting device. The weight of the selector is a
maximum of 270 kg.

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5 Mounting

6. Remove the ring nuts from the selector.

Figure 22: Ring nut

7. NOTICE! Carefully lift selector below the oil compartment, ensuring that
the selector take-off leads are free when lifting the selector on the oil
compartment and do not touch the compartment. If this is not done, the
selector take-off leads may be damaged.

8. Align the position of both coupling parts and attachment points on the oil
compartment and the selector with one another. The correct position of
the two coupling parts is shown in the adjustment plans in the appendix.

9. Screw selector onto oil compartment.

Figure 23: Selector with oil compartment

10. Remove support on the underside of the change-over selector.

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5 Mounting

5.2.1.3

Securing selector on oil compartment (selector size E)

1. CAUTION! Place the selector on a level surface and secure it
against tipping. An unstably positioned selector may tip, resulting in seri­ous injuries and damage.

2. Remove red-colored packaging material and transport material from se­lector.

3. Remove plastic bag with fastening materials from the selector and keep
them ready.

Figure 24: Plastic bag with fastening materials

4. Remove the blocking strip from the selector coupling. Once the blocking
strip is removed, the selector coupling must no longer be turned.

Figure 25: Blocking strip

5. Place the selector on the lifting device. The weight of the selector is a
maximum of 465 kg.

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5 Mounting

6. Remove the ring nuts from the selector.

Figure 26: Ring nut

7. NOTICE! Carefully lift selector below the oil compartment, ensuring that
the selector take-off leads are free when lifting the selector on the oil
compartment and do not touch the compartment. If this is not done, the
selector take-off leads may be damaged.

8. Align the position of both coupling parts and attachment points on the oil
compartment and the selector with one another. The correct position of
the two coupling parts is shown in the adjustment plans in the appendix.

9. Screw selector onto oil compartment.

Figure 27: Selector with oil compartment

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5 Mounting

5.2.1.4

Connecting tap selector take-off leads

Proceed as follows to connect the tap selector take-off leads:

1. NOTICE! Screw tap selector take-off lead to connecting piece with care.
Comply with specified tightening torque and secure screw connection.
Failure to do so may result in damage to the on-load tap-changer and
transformer.

2. Attach screening caps to screw connection.

Figure 28: Tap selector take-off lead

5.2.2

NOTICE

5.2.2.1

Connecting tap winding and on-load tap-changer take-off lead

Damage to the on-load tap-changer!

Connecting leads which place mechanical strain on the on-load tap-changer
will damage the on-load tap-changer!

► Produce connections with care.

► Do not twist connection contacts.

► Connect connecting leads without warping or deforming.

► If necessary use an expansion loop for connecting leads.

► Fit screening caps provided to screw connections.

Connect tap winding and on-load tap-changer take-off lead in accordance
with the connection diagram included with the delivery.

Tap selector connection contacts for selector size C/D

The tap selector connection contacts are provided with a through-hole for
M12 screws. The screening caps are supplied separately.

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5 Mounting

Figure 29: Tap selector connection contacts

5.2.2.2

Change-over selector connection contacts for reversing change-over selector connection for selector size C/D

The (+) and (-) change-over selector connection contacts are designed like
tap selector connection contacts for reversing change-over selector connec­tions. The change-over selector connection contacts (0) are produced as ter­minal lugs of the crimped connecting lead (=0/K) with a through-hole for M12
screws.

The screening caps are supplied separately.

Figure 30: Change-over selector connection contacts for reversing change-over se­lector connection

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5 Mounting

5.2.2.3

5.2.2.4

Change-over selector connection contacts for coarse change-over selector connection for selector size C/D

For coarse change-over selector connection, the (0) and (–) change-over se­lector connection contacts are designed like the tap selector connection con­tacts. The change-over selector connection contacts (+) are produced as ter­minal lugs of the crimped connecting lead (+/K) with a through-hole for M12
screws.

The screening caps are supplied separately.

Figure 31: Change-over selector connection contacts for coarse change-over selec­tor connection

Tap selector connection contacts and change-over selector connection contacts for selector size E

The tap selector connection contacts and change-over selector connection
contacts are labeled on the selector bars. The connection is made at the
thread stud of the selector connection contact via cable shoes and locknuts.

Every connection point must be covered by a screening cap. The screening
caps are designed for lateral connection with a straight cable shoe or for
front connection with an angled cable shoe.

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5 Mounting

Figure 32: Tap selector connection contacts and change-over selector connection
contacts

5.2.2.5

Each screening cap is attached with a steel angle piece and 2 screws. The
connection is secured by centre-punching at the perimeter of the screw
head. The distance between the screening caps and adjacent selector take­off leads must be at least 25 mm!

Figure 33: Screening caps

Bridges for parallel connection of selector planes

If bridges for the parallel connection of selector planes are needed for tech­nical reasons or have been ordered, the selector is supplied with the bridges
and screening caps already fitted.

Detailed information about the bridges is available in the appendix.

Also refer to

2 OILTAP® R, R I 2002/2003-E, R I 3003-E, bridges for parallel connec-

tion of selector plane (898713) [► 193]

2 OILTAP® R, R I 2002/2003-C/D, R I 3003-C/D, bridges for parallel con-

nection of selector plane (896706) [► 192]

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5 Mounting

5.2.2.6

Connecting on-load tap-changer take-off lead

There are through-holes 13 mm in diameter at several points in the take-off
ring of the oil compartment for connecting the on-load tap-changer take-off
lead.

Proceed as follows to connect the on-load tap-changer take-off lead:

1. Connect the on-load tap-changer take-off lead to any through-hole on
the take-off ring of the oil compartment.

2. Secure screw connection.

5.2.3

Figure 34: Take-off ring on oil compartment

Carrying out the transformer ratio test

We recommend carrying out a transformer ratio test before the transformer
is dried. The following types of transformer ratio test are possible:

▪ Transformer ratio test with TAPMOTION® TD test drive

▪ Manual transformer ratio test

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5 Mounting

5.2.3.1

NOTICE

5.2.3.2

Carrying out transformer ratio test with TAPMOTION® TD test drive

Damage to the on-load tap-changer!

Performing too many operations without complete oil filling will damage the
on-load tap-changer!

► Do not perform more than 250 tap-change operations on the on-load

tap-changer without oil before drying.

► Before first actuating the on-load tap-changer after drying the trans-

former, the tap selector and change-over selector (if present) must be
completely immersed in transformer oil and the oil compartment must
be completely filled with oil.

After the transformer ratio test, open the kerosene drain plug in the oil com­partment if the on-load tap-changer is to be dried with kerosene in the trans­former tank. After drying, the diverter switch insert must be removed, the
kerosene drain plug in the oil compartment closed and the diverter switch
insert refitted.

In order to run the transformer ratio test, we recommend using the
TAPMOTION® TD test drive. The precise process is described in the test
drive operating instructions.

Carrying out the transformer ratio test manually

NOTICE

Damage to the on-load tap-changer!

Performing too many operations without complete oil filling will damage the
on-load tap-changer!

► Do not perform more than 250 tap-change operations on the on-load

tap-changer without oil before drying.

► Before first actuating the on-load tap-changer after drying the trans-

former, the tap selector and change-over selector (if present) must be
completely immersed in transformer oil and the oil compartment must
be completely filled with oil.

To actuate the drive shaft of the upper gear unit of the on-load tap-changer
head, you can use a short tube (diameter 25 mm) with screwed-in coupling
bolt (diameter 12 mm) with a hand wheel or crank.

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5 Mounting

Figure 35: Upper gear unit with hand crank

If using more than one on-load tap-changer column with a shared drive, you
have to link all on-load tap-changer heads to one another by the horizontal
drive shaft part.

1. NOTICE! Only move on-load tap-changer into the desired operating po­sition via drive shaft of the upper gear unit. When using a drill, do not
exceed a maximum speed of 250 rpm. The diverter switch operation can
be heard distinctly.

2. NOTICE! After operating the diverter switch, continue to crank 2.5 revo­lutions in the same direction on the drive shaft of the upper gear unit in
order to correctly end the tap change operation. An incomplete tap­change operation may damage the on-load tap-changer!

When actuating the change-over selector a higher torque is required.

3. NOTICE! Carry out the transformer ratio test in all operating positions.
Always check the operating position reached through the inspection win­dow in the on-load tap-changer head cover. Never overshoot the end
positions, which are indicated in the connection diagram supplied with
the delivery.

Figure 36: Inspection window

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5 Mounting

4. Once the transformer ratio test is complete, return on-load tap-changer
to its adjustment position (see supplied connection diagram of the on­load tap-changer).

After the transformer ratio test, open the kerosene drain plug in the oil com­partment if the on-load tap-changer is to be dried with kerosene in the trans­former tank. After drying, the diverter switch insert must be removed, the
kerosene drain plug in the oil compartment closed and the diverter switch
insert refitted.

5.2.4

Measuring DC resistance on transformer

Note the measurement scenarios listed below and the associated maximum
measured currents when measuring DC resistance on the transformer.

The measured DC current is normally restricted to 10 % of the rated current
of the measured transformer winding in order to prevent the winding from
overheating.

Measure the DC resistance in the various on-load tap-changer operating po­sitions. You need to distinguish here whether the measured current is inter­rupted when changing operating position or not.

Without interruption

in measured current

Oil compartment emp-tyMaximum 10 A DC Maximum 50 A DC

Oil compartment filled
with insulating oil

Table 7: Maximum permitted measured currents when measuring DC resistance on
transformer

Maximum 50 A DC Maximum 50 A DC

With interruption
(measured current =
0 A before change in
operating position)

5.2.5

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Drying on-load tap-changer in autoclave

Dry on-load tap-changer using the following instructions to ensure the dielec­tric values assured by MR on the on-load tap-changer.

If you want to dry the on-load tap-changer in an autoclave, first perform the
drying process and then complete transformer assembly.

If drying in an autoclave, the following methods are possible:

▪ Vacuum-drying

▪ Vapor-phase drying

5 Mounting

5.2.5.1

Vacuum-drying in the autoclave

Before starting vacuum-drying in the autoclave, you must remove the on­load tap-changer head cover and on-load tap-changer accessories:

1. NOTICE! Remove the on-load tap-changer head cover (24 screws M10/
wrench size 17 with safety elements) and store it outside the autoclave.
If this is not done, the on-load tap-changer head cover may be dam­aged.

2. NOTICE! Remove on-load tap-changer accessories and store outside
autoclave: motor-drive unit, drive shaft, protective relay, pressure moni­toring device, pressure relief device, bevel gear, temperature sensor, oil
filter unit. If this is not done, the on-load tap-changer accessories may
be damaged.

Vacuum-drying in the autoclave

1. Heat up the on-load tap-changer in air at atmospheric pressure with a
temperature increase of about 10 °C/h to a final temperature of maxi­mum 110 °C.

2. Pre-dry the on-load tap-changer in circulating air at a max. temperature
of 110 °C for a period of 20 hours.

3. Vacuum dry on-load tap-changer at between 105 °C and maximum 125
°C for at least 50 hours.

4. Residual pressure of no more than 10-3 bar.

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5.2.5.2

Vapor-phase drying in the autoclave

For vapor-phase drying in the autoclave, you must open the kerosene drain
plug in the oil compartment base before drying so that the kerosene conden­sate can drain from the oil compartment.

1. NOTICE! Unscrew kerosene drain plug between oil compartment base
and selector gear clockwise until it starts to get hard to turn. Never un­screw the kerosene drain plug all the way.

Figure 37: Kerosene drain plug

2. NOTICE! Remove the on-load tap-changer head cover (24 screws M10/
wrench size 17 with safety elements) and store it outside the autoclave.
If this is not done, the on-load tap-changer head cover may be dam­aged.

3. NOTICE! Remove on-load tap-changer accessories (motor-drive unit,
drive shaft, protective relay, pressure monitoring device, pressure relief
device, bevel gear, temperature sensor, oil filter unit) and store outside
autoclave. If this is not done, the on-load tap-changer accessories may
be damaged.

Vapor-phase drying in the autoclave

1. Supply kerosene vapor at a temperature of around 90 °C. Keep this
temperature constant for 3 to 4 hours.

2. Increase the kerosene vapor temperature by approx. 10 °C/hour to the
desired final temperature (125 °C maximum on the on-load tap-chang­er).

3. Vacuum dry on-load tap-changer at between 105 °C and maximum 125
°C for at least 50 hours.

4. Residual pressure of no more than 10-3 bar.

NOTICE! Close kerosene drain plug (tightening torque 20 Nm). An open

kerosene drain plug leads to oil escaping from the oil compartment and
therefore to damage to the on-load tap-changer and transformer.

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5.2.6

Drying on-load tap-changer in transformer tank

Dry on-load tap-changer using the following instructions to ensure the dielec­tric values assured by MR on the on-load tap-changer.

If you want to dry the on-load tap-changer in the transformer tank, first com­plete transformer assembly and then undertake drying.

If drying in the transformer tank, the following methods are possible:

▪ Vacuum-drying

▪ Vapor-phase drying

5.2.6.1

Vacuum-drying in the transformer tank

Before you start vacuum-drying in the transformer tank, you must place a
connecting lead between the corresponding pipe connections and seal off
the pipe connections not being used with blank covers.

The on-load tap-changer head cover remains closed during the entire drying
process.

1. Establish a connecting lead either between connections E2 and Q or
connections E2 and R on the on-load tap-changer head.

2. Seal off unused pipe connections with a suitable blank cover.

Figure 38: Connecting lead

Vacuum-drying in the transformer tank

1. Heat up the on-load tap-changer in air at atmospheric pressure with a
temperature increase of about 10 °C/h to a final temperature of maxi­mum 110 °C.

2. Pre-dry the on-load tap-changer in circulating air at a max. temperature
of 110 °C for a period of 20 hours.

3. Vacuum dry on-load tap-changer at between 105 °C and maximum 125
°C for at least 50 hours.

4. Residual pressure of no more than 10-3 bar.

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5.2.6.2

5.2.6.2.1

5.2.6.2.1.1

Vapor-phase drying in the transformer tank

For vapor-phase drying in the transformer tank, you have to open the kero­sene drain plug before drying so that the kerosene condensate can drain
from the oil compartment.

The kerosene drain plug is located in the oil compartment base and is not
generally accessible from the outside. For this reason, you first have to re­move the diverter switch insert, open the kerosene drain plug, and then in­stall the diverter switch insert again. After the drying process, you have to re­move the diverter switch insert again to close the kerosene drain plug.

If you have already opened the kerosene drain plug in the transformer for
vapor-phase drying in the transformer tank when installing the on-load tap­changer, you can start the drying operation directly.

Removing diverter switch insert

Proceed as follows to remove the diverter switch insert.

Moving on-load tap-changer to adjustment position

► Move on-load tap-changer to adjustment position.

Figure 39: Adjustment position

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5.2.6.2.1.2

WARNING

NOTICE

Removing on-load tap-changer head cover

Danger of death or severe injury!

Danger of death or severe injury from explosive gases under the on-load
tap-changer head cover!

► Ensure that there are no naked flames, hot surfaces or sparks (for ex-

ample caused by static charging) in the immediate surroundings and
that none occur.

► De-energize all auxiliary circuits (for example tap-change supervisory

control, pressure relief device, pressure-operated relays) before remov­ing the on-load tap-changer head cover.

► Do not operate any electric devices during the work (for example risk of

sparks caused by impact wrench).

► Only use conductive and grounded hoses, pipes and pump equipment

that are approved for flammable liquids.

Damage to the on-load tap-changer and transformer!

Small parts in the oil compartment may block the diverter switch insert,
thereby damaging the on-load tap-changer and transformer!

► Take care to avoid parts falling into the oil compartment.

► Check that you have the same number of small parts when disassem-

bling and reassembling.

1. Make sure that the inspection window is sealed with the cover.

2. Loosen screws with safety elements on the on-load tap-changer head
cover.

Figure 40: On-load tap-changer head cover

3. NOTICE! Remove on-load tap-changer head cover. Check that the
sealing surfaces on the on-load tap-changer head cover and on-load
tap-changer head are in sound condition when removing and during all

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other work. Ensure that o-ring is in sound condition too. Damaged seal­ing surfaces lead to oil escaping and therefore to on-load tap-changer
and transformer damage.

Figure 41: On-load tap-changer head cover

5.2.6.2.1.3

4. NOTICE! Do not expose the open oil compartment to ambient humidity
for more than 10 hours. If you do, this may result in damage to the on­load tap-changer and transformer due to insufficient dielectric strength
of the diverter switch oil.

Removing the tap position indicator

► Pull the spring clip off the shaft end and remove the tap position indica-

tor disk.

Figure 42: Tap position indicator disk

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5.2.6.2.1.4

WARNING

NOTICE

Disconnecting the plug connector of the tap-change supervisory control

Danger of death or severe injury!

Danger of death or severe injury from explosive gases under the on-load
tap-changer head cover!

► Ensure that there is no supply voltage on the tap-change supervisory

control.

Damage to on-load tap-changer resulting from defective tap­change supervisory control!

Disconnecting the tap-change supervisory control without due care may
damage it, thereby resulting in damage to the on-load tap-changer and
transformer!

► Disconnect tap-change supervisory control with care in order not to

damage or rip out the connecting leads.

1. Lift plug connector and leads out of bracket and retaining clamps.

Figure 43: Lifting out plug connector

2. Disconnect the plug connector.

Figure 44: Disconnecting plug connector

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3. Put part B of plug connector back in bracket.

Figure 45: Placing part B of plug connector in bracket

4. Swivel part A of plug connector out of on-load tap-changer head in di­rection indicated by arrow until it is between the pipe connections and
the cable cannot be damaged when pulling out the diverter switch insert.

5.2.6.2.1.5

Figure 46: Swiveling out part A of plug connector

Lifting out diverter switch insert

1. Loosen bolts and safety elements on carrier plate of diverter switch in­sert.

NOTICE! Make sure that parts do not fall into the oil compartment.

Parts in the oil compartment may block the diverter switch insert, there­by damaging the on-load tap-changer and transformer. Check that you
have the same number of parts when disassembling and reassembling.

Figure 47: Carrier plate of diverter switch insert

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2. Insert the lifting gear in the brackets provided on the diverter switch in­sert carrier plate and position vertically above the diverter switch insert.

Figure 48: Brackets on carrier plate

3. Lift out the diverter switch insert slowly and vertically.

Figure 49: Lifting out diverter switch insert

4. CAUTION! Place the diverter switch insert on a level surface and se­cure it against tipping. An unstably positioned diverter switch insert may
tip, resulting in injuries and damage.

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5.2.6.2.2

5.2.6.2.3

Opening kerosene drain plug

► NOTICE! Unscrew kerosene drain plug with extended socket wrench

counter-clockwise until it starts to get hard to turn.Never unscrew the
kerosene drain plug all the way.

Figure 50: Kerosene drain plug

Inserting diverter switch insert

Proceed as follows to insert the diverter switch insert.

5.2.6.2.3.1

Inserting diverter switch insert

1. To fit the diverter switch insert, ensure that the selector coupling and in­dicator gear are in the adjustment position.

Figure 51: Adjustment position

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2. Insert the lifting gear in the brackets provided on the diverter switch in­sert carrier plate and position vertically above the diverter switch insert.

Figure 52: Brackets on carrier plate

3. Ensure that the red triangles on the coupling and carrier plate match up.

Figure 53: Coupling

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4. Align diverter switch insert such that the red triangles at the top of the
energy accumulator and on the on-load tap-changer head are opposite
one another.

Figure 54: Aligning diverter switch insert

5. Slowly lower diverter switch insert.

6. Secure carrier plate of diverter switch insert with bolts and safety ele­ments.

Carrier plate of diverter switch insert

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5.2.6.2.3.2

Connecting tap-change supervisory control plug connector

1. Lift part B of plug connector out of bracket.

Figure 55: Part B of plug connector

2. Connecting plug connector

Figure 56: Connecting plug connector

5.2.6.2.3.3

3. Place plug connector in bracket, secure leads on both sides of plug con­nector in retaining clamps.

Figure 57: Placing plug connector in bracket

Inserting the tap position indicator

Due to the coupling pin, the tap position indicator disk can only be installed
when in the correct position.

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► Place tap position indicator disk on indicator drive shaft, slide spring clip

on to shaft end.

Figure 58: Tap position indicator disk

5.2.6.2.3.4

Securing on-load tap-changer head cover

1. NOTICE! Place the on-load tap-changer head cover on the on-load tap­changer head and take care not to damage the o-ring inserted in the on­load tap-changer head cover. A damaged o-ring will cause oil to escape
from the diverter switch oil compartment, resulting in on-load tap-chang­er damage. Also ensure that the red triangular marks on the on-load
tap-changer head and the on-load tap-changer head cover match up.

Figure 59: On-load tap-changer head cover with o-ring

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2. Screw on-load tap-changer head cover using screws and safety ele­ments.

Figure 60: On-load tap-changer head cover

5.2.6.2.4

Drying the on-load tap-changer

1. Connect pipe connections R and Q of on-load tap-changer head to the
kerosene vapor lead using one shared lead.

2. Seal off unused pipe connections with a suitable blank cover.

Figure 61: Shared lead

Vapor-phase drying in the transformer tank

1. Supply kerosene vapor at a temperature of around 90 °C. Keep this
temperature constant for 3 to 4 hours.

2. Increase the kerosene vapor temperature by approx. 10 °C/hour to the
desired final temperature (125 °C maximum on the on-load tap-chang­er).

3. Vacuum dry on-load tap-changer at between 105 °C and maximum 125
°C for at least 50 hours.

4. Residual pressure of no more than 10-3 bar.

5.2.6.2.5

Closing kerosene drain plug

1. Remove diverter switch insert.

2. Close kerosene drain plug with extended socket wrench by turning
clockwise (tightening torque 20 Nm).

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3. Insert diverter switch insert.

Installing the on-load tap-changer in the transformer (bell-

5.3
type tank version)

The following chapters explain how to install the on-load tap-changer in the
transformer (bell-type tank version).

5.3.1

5.3.1.1

Inserting on-load tap-changer into supporting structure

Proceed as follows to insert the on-load tap-changer in the supporting struc­ture:

Securing selector on oil compartment (selector size C/D)

1. CAUTION! Place the selector on a level surface and secure it

against tipping. An unstably positioned selector may tip, resulting in seri­ous injuries and damage.

2. Remove red-colored packaging material and transport material from se-

lector.

3. Remove plastic bag with fastening materials from the selector and keep

them ready.

Figure 62: Plastic bag with fastening materials

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4. Remove the ring nuts from the selector.

Figure 63: Ring nut

5. Remove the blocking strip from the selector coupling. Once the blocking
strip is removed, the selector coupling must no longer be turned.

Figure 64: Blocking strip

6. CAUTION! Place the oil compartment on a level surface and secure
it against tipping. An unstably positioned oil compartment may tip over,
resulting in serious injuries and damage.

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7. Lift the oil compartment by hooking up the on-load tap-changer head
and remove the blocking device on the coupling of the oil compartment
base.

Figure 65: Blocking plate and shackle

8. Carefully raise oil compartment above selector.

9. Align the position of both coupling parts and attachment points on the oil
compartment and the selector with one another. The correct position of
the two coupling parts is shown in the adjustment plans in the appendix.

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10. Screw selector onto oil compartment.

5 Mounting

5.3.1.2

Figure 66: Selector with oil compartment

Securing selector on oil compartment (selector size E)

1. CAUTION! Place the selector on a level surface and secure it
against tipping. An unstably positioned selector may tip, resulting in seri­ous injuries and damage.

2. Remove red-colored packaging material and transport material from se­lector.

3. Remove plastic bag with fastening materials from the selector and keep
them ready.

Figure 67: Plastic bag with fastening materials

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4. Remove the ring nuts from the selector.

Figure 68: Ring nut

5. Remove the blocking strip from the selector coupling. Once the blocking
strip is removed, the selector coupling must no longer be turned.

Figure 69: Blocking strip

6. NOTICE! Place the oil compartment on a level surface and secure it
against tipping. An unstably positioned oil compartment may tip over, re­sulting in serious injuries and damage.

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7. Lift the oil compartment by hooking up the on-load tap-changer head
and remove the blocking device on the coupling of the oil compartment
base.

Figure 70: Blocking plate and shackle

8. Carefully raise oil compartment above selector.

9. Align the position of both coupling parts and attachment points on the oil
compartment and the selector with one another. The correct position of
the two coupling parts is shown in the adjustment plans in the appendix.

10. Screw selector onto oil compartment.

Figure 71: Selector with oil compartment

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5.3.1.3

Connecting tap selector take-off leads

Proceed as follows to connect the tap selector take-off leads:

1. NOTICE! Screw tap selector take-off lead to connecting piece with care.
Comply with specified tightening torque and secure screw connection.
Failure to do so may result in damage to the on-load tap-changer and
transformer.

2. Attach screening caps to screw connection.

5.3.1.4

Figure 72: Tap selector take-off lead

Inserting on-load tap-changer into supporting structure

1. NOTICE! Using spacers, insert on-load tap-changer vertically into sup­porting structure (maximum 1° deviation from the vertical) so that the
on-load tap-changer reaches its final installation height and only has to
be raised a maximum of 5 to 20 mm after fitting the bell-type tank. If this
is not done, once the tap winding and on-load tap-changer take-off lead

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are connected tension may occur which will damage the on-load tap­changer and transformer. There is also a risk of malfunctions from se­lector contacts closing incorrectly.

Figure 73: On-load tap-changer with spacers on supporting structure

2. Remove red supports on selector base (if present).

3. Temporarily fasten on-load tap-changer to supporting structure. The
supporting flange has through holes for this purpose.

Figure 74: Fastening the on-load tap-changer

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5.3.2

NOTICE

5.3.2.1

Connecting tap winding and on-load tap-changer take-off lead

Damage to the on-load tap-changer!

Connecting leads which place mechanical strain on the on-load tap-changer
will damage the on-load tap-changer!

► Produce connections with care.

► Do not twist connection contacts.

► Connect connecting leads without warping or deforming.

► If necessary use an expansion loop for connecting leads.

► Fit screening caps provided to screw connections.

Connect tap winding and on-load tap-changer take-off lead in accordance
with the connection diagram included with the delivery.

Tap selector connection contacts for selector size C/D

The tap selector connection contacts are provided with a through-hole for
M12 screws. The screening caps are supplied separately.

Figure 75: Tap selector connection contacts

5.3.2.2

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Change-over selector connection contacts for reversing change-over selector connection for selector size C/D

The (+) and (-) change-over selector connection contacts are designed like
tap selector connection contacts for reversing change-over selector connec­tions. The change-over selector connection contacts (0) are produced as ter­minal lugs of the crimped connecting lead (=0/K) with a through-hole for M12
screws.

The screening caps are supplied separately.

5 Mounting

Figure 76: Change-over selector connection contacts for reversing change-over se­lector connection

5.3.2.3

5.3.2.4

Change-over selector connection contacts for coarse change-over selector connection for selector size C/D

For coarse change-over selector connection, the (0) and (–) change-over se­lector connection contacts are designed like the tap selector connection con­tacts. The change-over selector connection contacts (+) are produced as ter­minal lugs of the crimped connecting lead (+/K) with a through-hole for M12
screws.

The screening caps are supplied separately.

Figure 77: Change-over selector connection contacts for coarse change-over selec­tor connection

Tap selector connection contacts and change-over selector connection contacts for selector size E

The tap selector connection contacts and change-over selector connection
contacts are labeled on the selector bars. The connection is made at the
thread stud of the selector connection contact via cable shoes and locknuts.

Every connection point must be covered by a screening cap. The screening
caps are designed for lateral connection with a straight cable shoe or for
front connection with an angled cable shoe.

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Figure 78: Tap selector connection contacts and change-over selector connection
contacts

5.3.2.5

Each screening cap is attached with a steel angle piece and 2 screws. The
connection is secured by centre-punching at the perimeter of the screw
head. The distance between the screening caps and adjacent selector take­off leads must be at least 25 mm!

Figure 79: Screening caps

Bridges for parallel connection of selector planes

If bridges for the parallel connection of selector planes are needed for tech­nical reasons or have been ordered, the selector is supplied with the bridges
and screening caps already fitted.

Detailed information about the bridges is available in the appendix.

Also refer to

2 OILTAP® R, R I 2002/2003-E, R I 3003-E, bridges for parallel connec-

tion of selector plane (898713) [► 193]

2 OILTAP® R, R I 2002/2003-C/D, R I 3003-C/D, bridges for parallel con-

nection of selector plane (896706) [► 192]

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5.3.2.6

Connecting on-load tap-changer take-off lead

There are through-holes 13 mm in diameter at several points in the take-off
ring of the oil compartment for connecting the on-load tap-changer take-off
lead.

Proceed as follows to connect the on-load tap-changer take-off lead:

1. Connect the on-load tap-changer take-off lead to any through-hole on
the take-off ring of the oil compartment.

2. Secure screw connection.

5.3.3

Figure 80: Take-off ring on oil compartment

Carrying out the transformer ratio test

We recommend carrying out a transformer ratio test before the transformer
is dried. The following types of transformer ratio test are possible:

▪ Transformer ratio test with TAPMOTION® TD test drive

▪ Manual transformer ratio test

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5.3.3.1

NOTICE

5.3.3.2

Carrying out transformer ratio test with TAPMOTION® TD test drive

Damage to the on-load tap-changer!

Performing too many operations without complete oil filling will damage the
on-load tap-changer!

► Do not perform more than 250 tap-change operations on the on-load

tap-changer without oil before drying.

► Before first actuating the on-load tap-changer after drying the trans-

former, the tap selector and change-over selector (if present) must be
completely immersed in transformer oil and the oil compartment must
be completely filled with oil.

After the transformer ratio test, open the kerosene drain plug in the oil com­partment if the on-load tap-changer is to be dried with kerosene in the trans­former tank. After drying, the diverter switch insert must be removed, the
kerosene drain plug in the oil compartment closed and the diverter switch
insert refitted.

In order to run the transformer ratio test, we recommend using the
TAPMOTION® TD test drive. The precise process is described in the test
drive operating instructions.

Carrying out the transformer ratio test manually

NOTICE

Damage to the on-load tap-changer!

Performing too many operations without complete oil filling will damage the
on-load tap-changer!

► Do not perform more than 250 tap-change operations on the on-load

tap-changer without oil before drying.

► Before first actuating the on-load tap-changer after drying the trans-

former, the tap selector and change-over selector (if present) must be
completely immersed in transformer oil and the oil compartment must
be completely filled with oil.

To actuate the drive shaft of the upper gear unit of the on-load tap-changer
head, you can use a short tube (diameter 25 mm) with screwed-in coupling
bolt (diameter 12 mm) with a hand wheel or crank.

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Figure 81: Upper gear unit with hand crank

If using more than one on-load tap-changer column with a shared drive, you
have to link all on-load tap-changer heads to one another by the horizontal
drive shaft part.

1. NOTICE! Only move on-load tap-changer into the desired operating po­sition via drive shaft of the upper gear unit. When using a drill, do not
exceed a maximum speed of 250 rpm. The diverter switch operation can
be heard distinctly.

2. NOTICE! After operating the diverter switch, continue to crank 2.5 revo­lutions in the same direction on the drive shaft of the upper gear unit in
order to correctly end the tap change operation. An incomplete tap­change operation may damage the on-load tap-changer!

When actuating the change-over selector a higher torque is required.

3. NOTICE! Carry out the transformer ratio test in all operating positions.
Always check the operating position reached through the inspection win­dow in the on-load tap-changer head cover. Never overshoot the end
positions, which are indicated in the connection diagram supplied with
the delivery.

Figure 82: Inspection window

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4. Once the transformer ratio test is complete, return on-load tap-changer
to its adjustment position (see supplied connection diagram of the on­load tap-changer).

After the transformer ratio test, open the kerosene drain plug in the oil com­partment if the on-load tap-changer is to be dried with kerosene in the trans­former tank. After drying, the diverter switch insert must be removed, the
kerosene drain plug in the oil compartment closed and the diverter switch
insert refitted.

5.3.4

Measuring DC resistance on transformer

Note the measurement scenarios listed below and the associated maximum
measured currents when measuring DC resistance on the transformer.

The measured DC current is normally restricted to 10 % of the rated current
of the measured transformer winding in order to prevent the winding from
overheating.

Measure the DC resistance in the various on-load tap-changer operating po­sitions. You need to distinguish here whether the measured current is inter­rupted when changing operating position or not.

Without interruption

in measured current

Oil compartment emp-tyMaximum 10 A DC Maximum 50 A DC

Oil compartment filled
with insulating oil

Table 8: Maximum permitted measured currents when measuring DC resistance on
transformer

Maximum 50 A DC Maximum 50 A DC

With interruption
(measured current =
0 A before change in
operating position)

5.3.5

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Drying on-load tap-changer in autoclave

Dry on-load tap-changer using the following instructions to ensure the dielec­tric values assured by MR on the on-load tap-changer.

If you want to dry the on-load tap-changer in an autoclave, first perform the
drying process and then complete transformer assembly.

If drying in an autoclave, the following methods are possible:

▪ Vacuum-drying

▪ Vapor-phase drying

5 Mounting

5.3.5.1

Vacuum-drying in the autoclave

Before starting vacuum-drying in the autoclave, you must remove the on­load tap-changer head cover and on-load tap-changer accessories:

1. NOTICE! Remove the on-load tap-changer head cover (24 screws M10/
wrench size 17 with safety elements) and store it outside the autoclave.
If this is not done, the on-load tap-changer head cover may be dam­aged.

2. NOTICE! Remove on-load tap-changer accessories and store outside
autoclave: motor-drive unit, drive shaft, protective relay, pressure moni­toring device, pressure relief device, bevel gear, temperature sensor, oil
filter unit. If this is not done, the on-load tap-changer accessories may
be damaged.

Vacuum-drying in the autoclave

1. Heat up the on-load tap-changer in air at atmospheric pressure with a
temperature increase of about 10 °C/h to a final temperature of maxi­mum 110 °C.

2. Pre-dry the on-load tap-changer in circulating air at a max. temperature
of 110 °C for a period of 20 hours.

3. Vacuum dry on-load tap-changer at between 105 °C and maximum 125
°C for at least 50 hours.

4. Residual pressure of no more than 10-3 bar.

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5.3.5.2

Vapor-phase drying in the autoclave

For vapor-phase drying in the autoclave, you must open the kerosene drain
plug in the oil compartment base before drying so that the kerosene conden­sate can drain from the oil compartment.

1. NOTICE! Unscrew kerosene drain plug between oil compartment base
and selector gear clockwise until it starts to get hard to turn. Never un­screw the kerosene drain plug all the way.

Figure 83: Kerosene drain plug

2. NOTICE! Remove the on-load tap-changer head cover (24 screws M10/
wrench size 17 with safety elements) and store it outside the autoclave.
If this is not done, the on-load tap-changer head cover may be dam­aged.

3. NOTICE! Remove on-load tap-changer accessories (motor-drive unit,
drive shaft, protective relay, pressure monitoring device, pressure relief
device, bevel gear, temperature sensor, oil filter unit) and store outside
autoclave. If this is not done, the on-load tap-changer accessories may
be damaged.

Vapor-phase drying in the autoclave

1. Supply kerosene vapor at a temperature of around 90 °C. Keep this
temperature constant for 3 to 4 hours.

2. Increase the kerosene vapor temperature by approx. 10 °C/hour to the
desired final temperature (125 °C maximum on the on-load tap-chang­er).

3. Vacuum dry on-load tap-changer at between 105 °C and maximum 125
°C for at least 50 hours.

4. Residual pressure of no more than 10-3 bar.

NOTICE! Close kerosene drain plug (tightening torque 20 Nm). An open

kerosene drain plug leads to oil escaping from the oil compartment and
therefore to damage to the on-load tap-changer and transformer.

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WARNING

NOTICE

5.3.6

5.3.6.1

Removing on-load tap-changer head

Removing on-load tap-changer head cover

Danger of death or severe injury!

Danger of death or severe injury from explosive gases under the on-load
tap-changer head cover!

► Ensure that there are no naked flames, hot surfaces or sparks (for ex-

ample caused by static charging) in the immediate surroundings and
that none occur.

► De-energize all auxiliary circuits (for example tap-change supervisory

control, pressure relief device, pressure-operated relays) before remov­ing the on-load tap-changer head cover.

► Do not operate any electric devices during the work (for example risk of

sparks caused by impact wrench).

► Only use conductive and grounded hoses, pipes and pump equipment

that are approved for flammable liquids.

Damage to the on-load tap-changer and transformer!

Small parts in the oil compartment may block the diverter switch insert,
thereby damaging the on-load tap-changer and transformer!

► Take care to avoid parts falling into the oil compartment.

► Check that you have the same number of small parts when disassem-

bling and reassembling.

1. Make sure that the inspection window is sealed with the cover.

2. Remove temporary fastening and spacers and slowly lower on-load tap­changer.

Figure 84: Remove fastening

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3. Loosen screws with safety elements on the on-load tap-changer head
cover.

Figure 85: On-load tap-changer head cover

4. NOTICE! Remove on-load tap-changer head cover. Check that the
sealing surfaces on the on-load tap-changer head cover and on-load
tap-changer head are in sound condition when removing and during all
other work. Ensure that o-ring is in sound condition too. Damaged seal­ing surfaces lead to oil escaping and therefore to on-load tap-changer
and transformer damage.

Figure 86: On-load tap-changer head cover

5. NOTICE! Do not expose the open oil compartment to ambient humidity
for more than 10 hours. If you do, this may result in damage to the on­load tap-changer and transformer due to insufficient dielectric strength
of the diverter switch oil.

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WARNING

5.3.6.2

5.3.6.3

Removing the tap position indicator

► Pull the spring clip off the shaft end and remove the tap position indica-

tor disk.

Figure 87: Tap position indicator disk

Disconnecting the plug connector of the tap-change supervisory control

Danger of death or severe injury!

Danger of death or severe injury from explosive gases under the on-load
tap-changer head cover!

► Ensure that there is no supply voltage on the tap-change supervisory

control.

NOTICE

Damage to on-load tap-changer resulting from defective tap­change supervisory control!

Disconnecting the tap-change supervisory control without due care may
damage it, thereby resulting in damage to the on-load tap-changer and
transformer!

► Disconnect tap-change supervisory control with care in order not to

damage or rip out the connecting leads.

1. Lift plug connector and leads out of bracket and retaining clamps.

Figure 88: Lifting out plug connector

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2. Disconnect the plug connector.

Figure 89: Disconnecting plug connector

3. Put part B of plug connector back in bracket.

5.3.6.4

Figure 90: Placing part B of plug connector in bracket

4. Swivel part A of plug connector out of on-load tap-changer head in di­rection indicated by arrow until it is between the pipe connections and
the cable cannot be damaged when pulling out the diverter switch insert.

Figure 91: Swiveling out part A of plug connector

Lifting out diverter switch insert

1. Loosen nuts and safety elements on carrier plate of diverter switch in­sert.

NOTICE! Make sure that parts do not fall into the oil compartment.

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Parts in the oil compartment may block the diverter switch insert, there­by damaging the on-load tap-changer and transformer. Check that you
have the same number of parts when removing and installing.

Figure 92: Carrier plate of diverter switch insert

2. Insert the lifting gear in the brackets provided on the diverter switch in­sert carrier plate and position vertically above the diverter switch insert.

Figure 93: Brackets on carrier plate

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3. Lift out the diverter switch insert slowly and vertically.

Figure 94: Lifting out diverter switch insert

4. CAUTION! Place the diverter switch insert on a level surface and se­cure it against tipping. An unstably positioned diverter switch insert may
tip, resulting in injuries and damage.

5.3.6.5

Removing the oil suction pipe

► Pull the connecting piece of the oil suction pipe in the on-load tap-

changer head inwards and out. Pay attention to the O-ring.

Figure 95: Oil suction pipe

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5.3.6.6

Lifting on-load tap-changer head off supporting flange

1. Remove nuts and safety elements between on-load tap-changer head
and supporting flange.

Figure 96: On-load tap-changer head

2. Lift on-load tap-changer head off supporting flange.

5.3.7

Figure 97: On-load tap-changer head

Attaching bell-type tank and connecting on-load tap-changer head with on-load tap-changer

The following chapters explain how to attach the bell-type tank and connect
the on-load tap-changer head with the on-load tap-changer.

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5.3.7.1

Mounting the bell-type tank

1. Clean sealing surface of supporting flange, place o-ring on supporting
flange.

Figure 98: Supporting flange with o-ring

2. Lift the bell-type tank over the active part of the transformer.

Figure 99: Bell-type tank

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5.3.7.2

Mounting on-load tap-changer head on bell-type tank

1. Clean sealing surfaces on mounting flange and on-load tap-changer
head, place oil-resistant gasket on mounting flange.

Figure 100: Mounting flange with gasket

1 Gasket 2 Mounting flange

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2. Position on-load tap-changer head on mounting flange such that the
markings on the supporting flange and on-load tap-changer head match
up. Note fitted bolt on supporting flange.

Figure 101: Markings and fitted bolt

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5.3.7.3

Connecting on-load tap-changer head and on-load tap-changer

1. NOTICE! Always lift the on-load tap-changer using the specified lifting
traverse. If the connection screws from the supporting flange are used
to lift the on-load tap-changer, the screws may be damaged, which
makes it impossible to properly screw the on-load tap-changer and the
on-load tap-changer head together!

Figure 102: On-load tap-changer head

2. Screw on-load tap-changer head to underlying supporting flange in the
area marked red using nuts and securing elements.

Figure 103: On-load tap-changer head

3. Remove lifting traverse.

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4. Screw on-load tap-changer head to mounting flange.

Figure 104: Screwing on-load tap-changer head to the mounting flange

5.3.7.4

Inserting oil suction pipe

1. Lightly grease the O-rings of the oil suction pipe.

2. Insert the oil suction pipe into the on-load tap-changer head. Make sure
the O-rings are correctly fitted.

Figure 105: Oil suction pipe

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5.3.7.5

Inserting diverter switch insert

1. To fit the diverter switch insert, ensure that the selector coupling and in­dicator gear are in the adjustment position.

Figure 106: Adjustment position

2. Insert the lifting gear in the brackets provided on the diverter switch in­sert carrier plate and position vertically above the diverter switch insert.

Figure 107: Brackets on carrier plate

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3. Ensure that the red triangles on the coupling and carrier plate match up.

Figure 108: Coupling

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4. Align diverter switch insert such that the red triangles at the top of the
energy accumulator and on the on-load tap-changer head are opposite
one another.

Figure 109: Aligning diverter switch insert

5. Slowly lower diverter switch insert.

6. Ensure correct position of carrier plate in on-load tap-changer head.
Area marked red must remain free.

7. Secure carrier plate of diverter switch insert with nuts and safety ele­ments.

Figure 110: Carrier plate of diverter switch insert

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5.3.7.6

Connecting tap-change supervisory control plug connector

1. Lift part B of plug connector out of bracket.

Figure 111: Part B of plug connector

2. Connecting plug connector

Figure 112: Connecting plug connector

5.3.7.7

3. Place plug connector in bracket, secure leads on both sides of plug con­nector in retaining clamps.

Figure 113: Placing plug connector in bracket

Inserting the tap position indicator

Due to the coupling pin, the tap position indicator disk can only be installed
when in the correct position.

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► Place tap position indicator disk on indicator drive shaft, slide spring clip

on to shaft end.

Figure 114: Tap position indicator disk

5.3.7.8

Securing on-load tap-changer head cover

1. NOTICE! Place the on-load tap-changer head cover on the on-load tap­changer head and take care not to damage the o-ring inserted in the on­load tap-changer head cover. A damaged o-ring will cause oil to escape
from the diverter switch oil compartment, resulting in on-load tap-chang­er damage. Also ensure that the red triangular marks on the on-load
tap-changer head and the on-load tap-changer head cover match up.

Figure 115: On-load tap-changer head cover with o-ring

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